97 4runner, front bumper build.

[97kurt]

Started working on this last monday and got some progress on it this weekend. I had been putting this build off for about two years while I saved up for coilovers and a winch. After seeing the shrockworks bumper I was inspired to get started.

Tin foil removed
http://www.kurtandnichole.com/gallery2/d/8259-2/IMG_4468.JPG

New cross member welded on, it is the main support/mounting spot for the bumper.
http://www.kurtandnichole.com/gallery2/d/8266-2/IMG_4470.JPG

In case anyone wanted to know, the xrc8 winch is clockable despite other rumors.
http://www.kurtandnichole.com/gallery2/d/8269-2/IMG_4471.JPG

Centered and clocked
http://www.kurtandnichole.com/gallery2/d/8275-2/IMG_4473.JPG

Got the height I wanted.
http://www.kurtandnichole.com/gallery2/d/8278-2/IMG_4474.JPG

Managed to keep it tight to the body.
http://www.kurtandnichole.com/gallery2/d/8281-2/IMG_4475.JPG

I really need to thank Nick for the picture. :angel:
http://www.kurtandnichole.com/gallery2/d/8293-2/IMG_4485.JPG

Lots of cardboard later
http://www.kurtandnichole.com/gallery2/d/8302-2/IMG_4491.JPG

http://www.kurtandnichole.com/gallery2/d/8311-2/IMG_4497.JPG

http://www.kurtandnichole.com/gallery2/d/8317-2/IMG_4499.JPG


So with any luck I will have it ready to be dropped at the powder coater on thursday morning. I just need to cut out the top plates, cut a hole for the winch line, finish the welding and flap disking. Drill the holes for my lights and find someone in town that can make a hoop for me.

[4x4mike]

Cool.
I like the looks of the Shrocks bumper but the price is keeping me from buying it. I imagine you've saved a bit of money and now have a custom bumper.

[cplvc]

Nice work :thumbup: Makes me want to take up welding :drool: What gauge steel plates are those?

[97kurt]

The main plate is 3/16, most of the sides and trim are just 12ga.

[garrett]

very nice, looks great

[Good Times]

loosk good kurt!

[BruceTS]

comming out great..... which brand flap disc do you use?

[97kurt]

comming out great..... which brand flap disc do you use?


You mean there is more than one brand?!?!?

I normally just use the dewalt 80 grits but yesterday I decided to grab a norton at home depot. It looks thicker than the dewalts and might last longer. I still need to find a place to buy bulk cut off discs.

[4runnerchevy]

I like the bumper, what are you doing to support the sides (wings) ? Just wondering about a side hit on a rock or another vehicle. Where I work we just get our disks, from our nut and bolt vendor Lawson. I am sure they just buy them from someone else and put thier lable on them. Cut off and flap disks get exspensive($2-4 bucks a pop), I am fortunate that my work supplies them.

[97kurt]

Each side has two pieces of 1"x1" square tube (.120 wall) to keep everything braced and happy.

[4runnerchevy]

ok!

[BruceTS]

comming out great..... which brand flap disc do you use?


You mean there is more than one brand?!?!?

I normally just use the dewalt 80 grits but yesterday I decided to grab a norton at home depot. It looks thicker than the dewalts and might last longer. I still need to find a place to buy bulk cut off discs.


For cut-off disc, I use the one's HF sells, they last the longest out of all the one's I've tested.

For flap disc, Lehigh Valley has the best bang for the buck http://www.lehighvalleyabrasives.com/servlet/StoreFront

Walter Flap disc are by far the best, but the cost vs longeivity don't add up.

[d0ubledown]

lookin good kurt! you using a 110v welder for your 3/16's?

[97kurt]

lookin good kurt! you using a 110v welder for your 3/16's?


You bet!! Never had an issue with the hobart 140 with that thickness. I have a 30 amp circuit that is 5 feet from the breaker and that helps a ton. I've also welded a lot of 1/4" wall DOM with that welder but I always pre-heat everything thicker than 3/16".

Anyways, my neighbor and I got the top of the bumper skinned and the winch line hole has been cut. Now begins the fun long process of welding and smoothing all the seams.

[97kurt]

http://www.kurtandnichole.com/gallery2/d/8323-2/IMG_4502.JPG

[Bob98SR5]

kurt,

nice dude. hey, why did u weld the main support vs making it a bolt on? I think about when i rear ended someone and the mounts twisting and deflecting and limiting the damage to the bumper and the mount

bob

[ToyFamily]

After seeing the shrockworks bumper I was inspired to get started.

I really need to thank Nick for the picture. :angel:
http://www.kurtandnichole.com/gallery2/d/8293-2/IMG_4485.JPG



HA HA thanks for the honor. Glad I can contribute to the Toy community. BTW, you can also pick up flap discs from the local welding stores they'll have a selection and I have found the discs with more flaps last alot longer, grit 80. Knock down the weld with a regular disc and do the finish work with it.

I'll have some of my friends in Carson come pick up my royalties ;)


Nick

[4runnerchevy]

kurt,

nice dude. hey, why did u weld the main support vs making it a bolt on? I think about when i rear ended someone and the mounts twisting and deflecting and limiting the damage to the bumper and the mount

bob


x2. I learned my lesson, a couple of times.

[97kurt]

kurt,

nice dude. hey, why did u weld the main support vs making it a bolt on? I think about when i rear ended someone and the mounts twisting and deflecting and limiting the damage to the bumper and the mount

bob


The new cross member is welded directly to the frame. And the main bumper support (2x2 3/16" angle iron) bolts to the new cross member in two spots. Then I tied in two more mounting points where the stock bumper attached to the frame.

I will have it off the truck tonight and get some better pics of it.

[Bob98SR5]

makes perfect sense, kurt. i was afraid that the whole thing was welded on :eeek:

[97kurt]

Well I am down to the little things that take the longest to complete. I need to fab something up to hold the winch control box and I think I am going to mount the HID ballasts inside the bumper also.



Then I still need to reinforce the areas where the plates come together and also get a hoop made.

http://www.kurtandnichole.com/gallery2/d/8346-2/IMG_4512.JPG

http://www.kurtandnichole.com/gallery2/d/8343-2/IMG_4511.JPG

[97kurt]

Started to reinforce everything this weekend. Bumper with out the winch only weighs 40lbs... So I am gonna add some beef to it.

http://www.kurtandnichole.com/gallery2/d/8349-2/IMG_4522.JPG

Decided to take it out today since the temp went up to 70 here in Reno... And of course I ran into some new issues with my truck. (drum brake issue and driveshaft making contact with the gas tank skid.)

http://www.kurtandnichole.com/gallery2/d/8367-2/IMG_4530.JPG

[Seanz0rz]

looks good!!!

as for the d-shaft and gastank, mines starting to do it over speed bumps. time for a bigger hammer.

[Whitey]

comming out great..... which brand flap disc do you use?


You mean there is more than one brand?!?!?

I normally just use the dewalt 80 grits but yesterday I decided to grab a norton at home depot. It looks thicker than the dewalts and might last longer. I still need to find a place to buy bulk cut off discs.


I have the hook-up on flap discs. Let me know what size you use. I've been working the the worlds leading abrasive manufacturer for the past 1o years.

[cplvc]

That bumper came out real nice. I think the shrockworks bumper I have without hoops weighs about 90-lbs and when I decide to add a winch not sure how the front suspension will hold that up. I believe my d-shaft is hitting the gas tank skid as well. My stock bumper was 10-lbs, so I'm sure the weight may be contributing to that, but I'm not 100% sure.

[97kurt]

Well its finally done!!! Got it back from the powder coater on thursday, then finished running the wires and converting my PIAA's to HID. The truck looks goofy with 265s so I am gonna start looking for a set of 285 or 295s for the end of this month.

http://www.kurtandnichole.com/gallery2/d/8407-2/IMG_4578_2.JPG


and


http://www.kurtandnichole.com/gallery2/d/8404-2/IMG_4579.JPG

[4Runner202020]

with the drive shaft thing mine was for all of a day. i hated that sound. so i took off the skid and used a angle grinder and just cut out the entier section of where it was hitting. it will never hit again and took all of ten min. lol better than a hammer i say.